Conductive Knitted Fabric Article and Method of Making the Same

ABSTRACT

A fabric article ( 100 ) comprising a continuous body of knitted fabric ( 100 ). The continuous body of fabric ( 100 ) comprises: a base component ( 101 ) comprising a plurality of courses of nonconductive yarn and a sensing component ( 107 ) comprising a first conductive region ( 109 ). The first conductive region ( 109 ) comprises at least one course of conductive yarn. The fabric article  100 ) is manufactured using a knitting machine comprising first and second needle beds. One or both of the first and second needle beds are used to knit the base component ( 101 ). The first needle bed is used to knit the first conductive region ( 109 ). A second conductive region ( 111 ) may be knit using the second needle bed. A conductive pathway ( 113 ) connecting the first conductive region ( 109 ) to the second conductive region ( 111 ) may be knit using the first or second needle bed.

The present invention is directed towards a fabric article and method of making the same. The present invention is directed, in particular, towards a fabric article comprising a non-conductive fabric base component and a sensing component attached to the base component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from United Kingdom Patent Application number 2005692.5 filed on 20 Apr. 2020, United Kingdom Patent Application number 2008008.1 filed on 28 May 2020, United Kingdom Patent Application number 2011235.5 filed on 21 Jul. 2021, and United Kingdom Patent Application number 2103301.4 filed on 10 Mar. 2021, the whole contents of which are incorporated herein by reference.

BACKGROUND

Fabric articles comprising sensing components can be designed to interface with a wearer of the article to determine information such as the wearer's heart rate and rate of respiration. The sensing components may comprise electrodes and connection terminals electrically connected together via an electrically conductive pathway. An electronics module for processing and communication can be removably coupled to the connection terminals so as to receive the measurement signals from the electrodes. The fabric articles may be incorporated into or form a wearable article such as a garment.

It is desirable to form conductive regions from conductive yarn that is knitted with a base fabric layer (base component) during a single knitting operation. This process simplifies the process of integrating electrodes into wearable articles and avoids the need for metallic or conductive polymer elements to be incorporated into a fabric. Conductive fabric electrodes are also comfortable to wear and can look, behave and feel like normal garment fabric.

Knitting conductive yarn is preferred over other techniques, such as weaving, as knitted structures are able to stretch without directly stretching the yarns used to form the knitted structure. Instead, when a knitted structure is stretched, the loops are deformed. This contrasts with woven articles where the yarns are directly stretched when the woven article is stretched. It will be appreciated that stretching a conductive yarn can change its electrical properties.

United States Patent Application Publication No. 2012/0144561 A1 discloses knitting techniques for forming three-dimensional textile electrodes. A conductive surface forming the electrode is knit using a back needle bed of a knitting machine while an isolating surface is knit using the front needle bed. A thread network is provided in a space formed between the conductive surface and the isolating surface using a tucking technique.

It is desirable to overcome at least some of the problems associated with the prior art, whether explicitly discussed herein or otherwise.

SUMMARY

According to the present disclosure there is provided a fabric article and method of making the same as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

According to a first aspect of the disclosure, there is provided a fabric article. The fabric article comprises a continuous body of knitted fabric. The continuous body of fabric comprises a base component comprising a non-conductive yarn and a sensing component comprising a first conductive region. The base component may comprise a plurality of courses of non-conductive yarn. The first conductive region may comprise at least one course of conductive yarn. Each course may comprise a plurality of stitches of yarn.

Advantageously, the present disclosure provides a continuous body of knitted fabric that comprises a sensing component integrally formed with the base component. This simplifies the manufacturing process as the sensing component and base component are manufactured during a single knitting operation. The fabric article structure simplifies the knitting techniques required to form the sensing component integrally with the base component. That is, the fabric article structure facilitates the manufacture of the continuous body of fabric in a single knitting operation.

Further, as the sensing component is knitted, the sensing component is able to stretch with the base component without the electrical properties (e.g. the resistivity) of the sensing component being affected. This is because when a knitted article is stretched, the yarn is not directly stretched, but rather the stitches are deformed. This contrasts with woven articles where the yarns are directly stretched when the woven article is stretched. It will be appreciated that stretching a conductive yarn can change its electrical properties.

Moreover, providing the sensing component as part of a singular fabric structure means that the fabric article may handle, feel, behave and looks like a fabric without requiring wiring, soldering or physical connections to provide the required sensing functionality.

The base component may be a double-knit base component. The double-knit structure means that the base component comprises first and second knitted layers that are interconnected. The double-knit structure provides strength and stability to the fabric article. The double-knit structure may be an interlock structure. The base component is not required to be double-knit and may have a single-knit, links, or ribbed structure for example.

The base component may comprise cardigan stitches. Advantageously, cardigan stitches have larger gaps and so can accommodate thicker conductive yarns. The conductive yarn has a yarn count of less than 15 nm. The conductive yarn may have a yarn count of less than 12 nm. The conductive yarn may have a yarn count of greater than 8 nm. The conductive yarn may have a yarn count of 10 nm. The conductive yarn may be a stainless-steel yarn.

The cardigan stitches may be half-cardigan stitches.

The cardigan stitches may be full-cardigan stitches.

The base component may be a non-conductive base component and may comprise only non-conductive yarn. Although conductive yarn may be incorporated into the base component if desired.

The first conductive region may be a three-dimensional conductive region that extends away from a first surface of the base component. The first conductive region may comprise a number P of courses of conductive yarn. P is a number greater than or equal to 1. The first and last course forming the first conductive region may be interconnected with the base component, and in particular, may be connected to the knit structure of the base component that defines the first surface of the base component from which the first conductive region extends. The first and last course may be the same course when P=1. The other courses forming the first conductive region may not be interconnected with the base component. P may be between 1 and 30, 5 and 30, 10 and 30, 15 and 30, or 25 and 30. P may be between 1 and 25, 1 and 20, 1 and 15, 1 and 10 or 1 and 5. Most preferably, P is between 10 and 20. The present disclosure is not limited to any particular number of courses. The number of courses may vary based on factors such as the thickness of the yarn or the machine gauge (number of needles per inch of the needle bed).

The first conductive region may extend to a height of between 0.2 mm and 30 mm from the first surface of the base component. The first conductive region may extend to a height of between 0.2 mm and 25 mm, 0.2 mm and 20 mm, 0.2 mm and 15 mm, 0.2 mm and 10mm, 0.2 mm and 5 mm, 0.2 mm and 2 mm, and 0.2 mm and 1 mm. The first conductive region may extend to a height of between 0.5 mm and 30 mm, 1 mm and 30 mm, 2 mm and 30 mm, 5 mm and 30 mm, 10 mm and 30 mm, 15 mm and 30 mm, 20 mm and 30 mm, and 25 mm and 30 mm. In some examples, the conductive region extends to a height of between 2 mm and 5 mm. The present disclosure is not limited to any particular height of conductive region. The height may vary based on factors such as the sensing application.

The first conductive region may form a tube extending from the first surface of the base component. The tube may have an apex spaced apart from the first surface. The first conductive region may define a convex outer surface. The tube may comprise one a plurality of courses of conductive yarn. Each course may comprise a plurality of stitches of yarn. The tube may have a generally elongate shape with a raised convex outer surface.

The first conductive region may form an electrode for monitoring activity at a body surface. The electrode may be a raised electrode that extends away from the first surface of the base component.

A filler material may be disposed within the first conductive region. That is, the filler material may be disposed in a spaced formed between the first conductive region and the base component. The continuous body of fabric may comprise the filler material. The filler material may comprise an expanding yarn. The filler material may comprise a plurality of tuck stitches of the expanding yarn. The filler material may comprise a plurality of float and tuck stitches of the expanding yarn. The expanding yarn may refer to a yarn that expands under the application of an external stimulus such as heat, pressure or steam. Preferably the yarn expands under the application of steam. The expanding yarn may comprise a polyester material. The expanding yarn may be a polyester filament yarn. Beneficially, the use of an expanding yarn means that after the fabric article is constructed, steam (for example) may be applied to cause the yarn to expand and bulk out the shape of the conductive region and provide further stability. As the yarn expands to fill the space between the first conductive region and the base layer, the space between the first conductive region and the base layer does not need to be densely packed with filler material during the knitting operation. Less yarn is required than if a non-expanding filler material were used. For example, a single strand of yarn (forming all or part of one course in the electrode) may provide the necessary support and stability function when the steam (for example) is applied.

The filler material may serve a stabilising function for the first conductive region in order to reduce noise and other electronic artefacts. The filer material may raise the profile of the first conductive region out from the base component and increase the quality, consistency and area of its contact against the skin surface. This is provided without requiring an increase in the amount of compression applied to the skin surface by the fabric article. Moreover, the expanding yarn can be integrally knit with the remainder of the continuous body of fabric which simplifies the manufacturing process and avoids the need to separately insert filler material after the continuous body of fabric is formed.

The sensing component may further comprise a second conductive region. The second conductive region may be a three-dimensional conductive region that extends away from a surface of the base component.

The second conductive region may comprise a number Q of courses of conductive yarn. Q is a number greater than or equal to 1. The first and last courses forming the second conductive region may be interconnected with the base component. The first and last course may refer to the same course when Q=1. The other courses forming the second conductive region may not be interconnected with the base component. Q may be between 1 and 15, 5 and 15, or 10 and 15. Q may be between 1 and 10 or 1 and 5. Most preferably, Q is between 5 and 10. The present disclosure is not limited to any particular number of courses.

The second conductive region may extend to a height of between 0.2 mm and 30 mm from a surface of the base component. The second conductive region may extend to a height of between 0.2 mm and 25 mm, 0.2 mm and 20mm, 0.2 mm and 15mm, 0.2 mm and 10mm, 0.2 mm and 5mm, 0.2 mm and 2 mm, and 0.2 mm and 1 mm. The second conductive region may extend to a height of between 0.5 mm and 30 mm, 1 mm and 30 mm, 2 mm and 30 mm, 5 mm and 30mm, 10mm and 30mm, 15mm and 30mm, 20mm and 30mm, and 25mm and 30mm In some examples, the conductive region extends to a height of between 1 mm and 2 mm. The present disclosure is not limited to any particular height of conductive region. The height may vary based on factors such as the sensing application.

A filler material may be disposed within the second conductive region. That is, the filler material may be disposed in a spaced formed between the second conductive region and the base component. The continuous body of fabric may comprise the filler material. The filler material may comprise an expanding yarn. The filler material may comprise a plurality of tuck stitches of the expanding yarn. The filler material may comprise a plurality of float and tuck stitches of the expanding yarn. The expanding yarn may refer to a yarn that expands under the application of heat, pressure or stream and preferably steam. The expanding yarn may comprise a polyester material. The expanding yarn may be a polyester filament yarn.

The second conductive region may form a connection terminal for electrically connecting with an electronics module. The connection terminal may form a raised connection terminal that extends away from the surface of the base component.

The second conductive region may form a tube extending from a surface of the base component. The tube may have an apex spaced apart from the surface. The second conductive region may define a convex outer surface. The tube may comprise one a plurality of courses of conductive yarn. Each course may comprise a plurality of stitches of yarn. The tube may have a generally elongate shape with a raised convex outer surface.

The second conductive region may be provided/extend from the first surface of the base component. The second conductive region may be provided/extend from the second surface of the base component. The first conductive region and the second conductive region may be provided on opposing surfaces of the base component.

The first conductive region may form an electrode and the second conductive region may form a connection terminal. The electrode and the connection terminal may be provided on opposing surfaces of the base component. This improves the mechanism by which an electronics module can be electrically connected to an electrode of the fabric article. Alternatively, the electrode and the connection terminal may be provided on the same surface of the base component.

The first conductive region may be a three-dimensional conductive region that extends away from a first surface of the base component. The second conductive region may be a three-dimensional conductive region that extends away from a second surface of the base component opposing the first surface.

The first and second conductive regions may be spaced apart from one another along a length of the fabric article. Length refers to the course/weft direction of the knitted fabric.

The first and second conductive regions may be electrically connected to one another by a conductive pathway. The sensing component may comprise the conductive pathway. That is, the conductive pathway may be part of the continuous body of fabric. The conductive pathway may extend along the length of one of the first and second surfaces of the base component between the first and second conductive regions. The conductive pathway may be flush with the base component and may extend within the body of the base component. The conductive pathway may extend along the first surface of the base component. The conductive pathway may extend along the weft direction of the continuous body of fabric. The conductive pathway may extend through the base component to electrically connect the first portion of conductive material to the second portion of conductive material.

The sensing component may be a unitary knitted structure formed form a single length of conductive yarn. This may mean that the first conductive region, second conductive region and/or conductive pathway are formed from the same conductive yarn during a single knitting operation. This simplifies the manufacturing process and increases the comfort of the fabric article as elements such as wires and hardware connectors are not required.

The conductive pathway may comprise a number R of courses of conductive yarn. R is a number greater than or equal to 1. The first and last courses forming the conductive pathway may be interconnected with the base component. The first and last courses may be the same course. R may be between 1 and 5, 1 and 4, 1 and 3 or 1 and 2. R may be between 2 and 5, 3 and 5 or 4 and 5. Most preferably, R is 1. Having R=1 keeps the profile of the conductive pathway low and flush against the base component. The present disclosure is not limited to any particular number of courses.

The conductive pathway may be provided on the first surface or second surface of the base component.

The height by which the conductive pathway extends away from the first surface or the second surface may be smaller than the height by which the first conductive region extends away from the first surface. The conductive pathway may be flush with or substantially flush with a surface of the base component. The conductive pathway may be provided within the base component and may be at least partially covered by the base component.

The first conductive region may be wider than the conductive pathway. Wider means wider in the warp direction. The second conductive region may be wider than the conductive pathway. The first conductive region may be wider than the second conductive region. The second conductive region may be wider than the first conductive region.

The conductive pathway may be longer than the first conductive region. Longer means longer in the course/weft direction. The conductive pathway may be longer than the second conductive region. The first conductive region may be longer than the second conductive region.

The first conductive region may be higher than the second conductive region and/or the conductive pathway. Height refers to the distance away from a surface of the base component. The second conductive region may be higher than the conductive pathway.

The continuous body of fabric is a knitted article and preferably a weft knitted article.

The base component of the unitary knitted structure may be a unitary knitted structured comprising one or more different types of non-conductive yarn.

The base component may comprise a combination of a non-conductive base yarn and an additional (non-conductive) stretch yarn. The stretch yarn may be an elastomeric yarn. The stretch yarn may impart elasticity/stretch into the fabric article. This means that the resultant fabric article is flexible and elasticated. This can enhance comfort and help ensure that the electrode is held in contact with the skin surface.

The base component may comprise a sealing/bonding yarn. The sealing/bonding yarn may be knitted around one or more of the edges of the fabric article. The sealing/bonding yarn may stop or reduce the likelihood of the base component from unravelling, laddering or unrolling. The sealing/bonding yarn may be melted to create a heat sealed final knitted course in the fabric article.

The fabric article may further comprise a gripper component provided on the first or second surface of the base component. The gripper component may be gripper yarn. The gripper yarn may be a silicone yarn or other yarn having a high friction non-slip outer surface. The gripper yarn may stop the base component from sliding against a skin surface. This may improve contact of the first conductive region of the sensing component with the skin surface.

The fabric article may comprise a plurality of sensing components. Each sensing component may comprise a first conductive region forming an electrode, a second conductive region forming a connection terminal, and a conductive pathway electrically connecting the first conductive region to the second conductive region.

One or more the plurality of sensing components may be separated from the fabric article to form separate fabric articles each comprising at least one sensing component. The base component may comprise drawthread to facilitate the separation of the fabric article.

The second surface of the base component may comprise a recess in the vicinity of the second conductive region. The recess may be sized to receive an interface element of the electronics module. The second conductive region may be provided in the recess. The interface element may be a conductive element of the electronics module arranged to interface with the second conductive region.

The fabric article may be a wearable article. The fabric article may be a garment.

The fabric article may be arranged to be integrated into a wearable article, optionally a garment. The fabric article may be arranged to be stitched, bonded or otherwise adhered to the wearable article.

According to a second aspect of the disclosure, there is provided a method of manufacturing a fabric article. The method comprises forming a continuous body of knitted fabric comprising a base component comprising a non-conductive yarn and a sensing component comprising a first conductive region. The base component may comprise a plurality of courses of non-conductive yarn. The first conductive region comprises at least one course of conductive yarn.

The fabric article may be manufactured using a knitting machine comprising a first bed of needles and a second bed of needles. The knitting machine may be a flat bed knitting machine. The first bed may be the front bed or the back bed of the knitting machine. The second bed may be the other of the front bed and the back bed of the knitting machine. The continuous body of fabric may be knitted using knitting operations performed by the first bed and the second bed of the knitting machine. The continuous body of fabric may be knitted using both the first bed and second bed of the knitting machine operating simultaneously in some regions and operating separately in other regions. Some regions may be knitted using only one of the first bed and the second bed.

Forming the continuous body of fabric may comprise knitting, using one or both of the first and second beds, non-conductive yarn to form the base component. The base component may be a double-knit base component. The double-knit base component may have an interlock structure. The double-knit base component may be formed by operating the first and second needle beds simultaneously.

Forming the continuous body of fabric may comprises knitting, using the first bed, conductive yarn to form the first conductive region. This step may be performed using the first bed only. That is, the second bed may not perform knitting operations on the body of fabric during this step. Knitting the conductive yarn may comprise knitting, using the first bed (only), one or a plurality of courses of conductive yarn to form a three-dimensional conductive region that extends away from a surface of the base component.

Forming the first conductive region may further comprise introducing a filler material into the first conductive region. This may comprise knitting an expanding yarn into the first conductive region. The knitting operation may comprise using tuck knits. The knitting operation may comprise an alternating sequence of tuck and float knits. The knitting operation may comprise an alternating sequence of tuck and float knits using first and second beds of the knitting machine.

Forming the continuous body of fabric may further comprise forming a second conductive region of the sensing component. Forming the second conductive region may comprises knitting, using the first or second bed, conductive yarn to form the second conductive region. The second conductive region may be knit using only one of the first and second beds.

Forming the second conductive region may comprise knitting, using the first bed (only), conductive yarn to form the second conductive region. The second conductive region is therefore formed on the same surface of the base component as the first conductive region.

Forming the second conductive region may comprise knitting, using the second bed (only), conductive yarn to form the second conductive region. The second conductive region is therefore formed on the opposing surface of the base component to the first conductive region.

Knitting the conductive yarn may comprise knitting, using the first or second bed (only), one or a plurality of courses of conductive yarn to form a three-dimensional conductive region that extends away from a surface of the base component to form the second conductive region.

Forming the second conductive region may further comprise introducing a filler material into the second conductive region. This may comprise knitting an expanding yarn into the second conductive region. The knitting operation may comprise using tuck knits. The knitting operation may comprise an alternating sequence of tuck and float knits. The knitting operation may comprise an alternating sequence of tuck and float knits using first and second beds of the knitting machine.

Forming the fabric article may further comprise forming a conductive pathway extending between and electrically connecting the first conductive region to the second conductive region. The conductive pathway may be part of the sensing component. That is, forming the continuous body of fabric may further comprise forming the conductive pathway of the sensing component.

The conductive pathway may be formed by knitting, using the first or second bed, one or more courses of conductive yarn. The conductive pathway may be knit using the first bed such that the conductive pathway extends along the first surface of the base component. The conductive pathway may be knit using the second bed such that the conductive pathway extends along the second surface of the base component. The other bed to the one use to knit the conductive pathway may pull the conductive yarn through the base component such that the conductive pathway extends through the base component and electrically connects the first conductive region to the second conductive region.

The sensing component may be formed from a single length of yarn that is knit into a plurality of courses.

The sensing component may be formed during the step of forming the base component. That is, the method may comprise forming part of the base component, then forming the sensing component, and then completing the formation of the base component.

Knitting the continuous body of fabric may comprise, in sequence:

-   -   Knitting one or a plurality of courses of the base component;     -   Knitting one or a plurality of courses of first conductive         region; and     -   Knitting one or a plurality of courses of the base component.

Knitting the continuous body of fabric may comprise, in sequence:

-   -   Knitting one or a plurality of courses of base component;     -   Knitting one or a plurality of courses of first conductive         region;     -   Knitting one or a plurality of courses of conductive pathway;     -   Knitting one or a plurality of courses of the first conductive         region; and     -   Knitting one or a plurality of courses of the base component.

Knitting the continuous body of fabric may comprise, in sequence:

-   -   Knitting one or a plurality of courses of the base component;     -   Knitting one or a plurality of courses of the first conductive         region;     -   Knitting one or a plurality of courses of the conductive         pathway;     -   Knitting one or a plurality of courses of the second conductive         region;     -   Knitting one or a plurality of courses of the conductive         pathway;     -   Knitting one or a plurality of courses of the first conductive         region; and     -   Knitting one or a plurality of courses of the base component.

In any of the above examples, the method may further comprise knitting one or a plurality of courses of expanding yarn to fill the first conductive region. For example, the knitting the continuous body of fabric may comprise, in sequence:

-   -   Knitting one or a plurality of courses of the base component;     -   Knitting one or a plurality of courses of the first conductive         region;     -   Knitting one or a plurality of courses of the conductive         pathway;     -   Knitting one or a plurality of courses of the second conductive         region;     -   Knitting one or a plurality of courses of expanding yarn to fill         the first conductive region;     -   Knitting one or a plurality of courses of the second conductive         region;     -   Knitting one or a plurality of courses of the conductive         pathway;     -   Knitting one or a plurality of courses of the first conductive         region; and     -   Knitting one or a plurality of courses of the base component.

In any of the above examples, knitting the continuous body of fabric may further comprise knitting one or more courses of sealing/bonding yarn to seal the edge of the base component.

In the above examples, knitting the courses of the base component may comprise: (a) knitting a course of base yarn using first and second needle beds (simultaneously); (b) knitting a course of elastomeric yarn using one of the first and second needle beds; and (c) knitting a course of elastomeric yarn using the other one of the first and second needle beds. The steps (a), (b), and (c) may be repeated any number of times as desired to provide the desired width of the continuous body of fabric. This is just one example knitting technique used to form a double-knit base component knit structure. This structure is beneficial in terms of the stability and ease of manufacture that it provides, but the present disclosure is not limited to this example technique.

In the above examples, knitting the courses of the first conductive region may comprise knitting one or a plurality of courses of conductive yarn using the first needle bed (only).

In the above examples, knitting the courses of the second conductive region may comprise knitting one or a plurality of courses of conductive yarn using the first needle bed (only) or the second needle bed (only).

In the above examples, knitting the courses of the conductive pathway may comprise knitting one or a plurality of courses of conductive yarn using the first needle bed (only) or the second needle bed (only). Preferably, the first needle bed (only) is used.

In the above examples, knitting the courses of expanding yarn may comprise knitting one or a plurality of courses of expanding yarn using an alternating sequence of tuck and float knits using the first and second needle beds. An external stimulus such as steam, heat or pressure may subsequently be applied to cause the expanding yarn to expand.

The method may further comprise forming a hole in the base component in the vicinity of the second conductive region. The hole may be sized to receive an interface element of an electronics module.

An indentation may be provided in the base component in the vicinity of the second conductive region. The indentation may be formed by a void in the second knit layer of the base component.

The first conductive region may form an electrode for monitoring activity at a body surface.

The second conductive region may form a connection terminal for electrically connecting with an electronics module.

The fabric article may be the fabric article of the first aspect of the disclosure.

A fabric article manufacturing according to the method of the second aspect of the disclosure is also provided.

According to a third aspect of the disclosure, there is provided a fabric article comprising a continuous body of knitted fabric. The continuous body of fabric comprises a base component and a sensing component. The base component defines a first surface and a second surface. The sensing component comprises a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the base component. The remaining courses of conductive yarn extend away from the first surface of the base component to form a raised conductive region.

The fabric article may comprise any of the features of the fabric article of the first aspect of the disclosure.

According to a fourth aspect of the disclosure, there is provided a method of manufacturing a fabric article. The method comprises forming a continuous body of fabric comprising a base component and a sensing component. The base component defines a first surface and a second surface. Forming the sensing component comprises knitting a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the base component. The remaining courses of conductive yarn extend away from the first surface of the base component to form a raised conductive region.

The fabric article may be the fabric article of the third aspect of the disclosure.

The method may comprise any of the features of the method of the second aspect of the disclosure.

A fabric article manufacturing according to the method of the fourth aspect of the disclosure is also provided.

According to a fifth aspect of the disclosure, there is provided a fabric article. The fabric article comprises a base component and a sensing component. The base component defines a first surface and a second surface. The sensing component comprises a first conductive region provided on the first surface of the base component. The sensing component comprises a second conductive region provided on the second surface of the base component. The sensing component comprises a conductive pathway extending from the first conductive region to the second conductive region and electrically connecting the first conductive region to the second conductive region. The first conductive region may form an electrode for monitoring activity at a body surface. The second conductive region may form a connection terminal for electrically connecting with an electronics module.

The fabric article may comprise any of the features of the fabric article of the first or second aspect of the disclosure.

According to a sixth aspect of the disclosure, there is provided a method of manufacturing a fabric article. The method comprises forming a base component. The base component defines a first surface and a second surface. The method comprises forming a sensing component. The sensing component comprises a first conductive region provided on the first surface of the base component. The sensing component comprises a second conductive region provided on the second surface of the base component. The sensing component comprises a conductive pathway extending from the first conductive region to the second conductive region and electrically connecting the first conductive region to the second conductive region.

The fabric article may be the fabric article of the fifth aspect of the disclosure.

The method may comprise any of the features of the method of the second or fourth aspect of the disclosure.

A fabric article manufacturing according to the method of the sixth aspect of the disclosure is also provided.

According to a seventh aspect of the disclosure, there is provided a computer program comprising instructions recorded thereon which, when executed by a computer associated with a knitting machine, are operable to cause the computer to control the knitting machine to perform the method of the second, fourth or sixth aspect of the disclosure.

According to an eighth aspect of the disclosure, there is provided a wearable article comprising:

a band arranged to surround a circumference of a wearer, the band comprising a continuous body of knitted fabric, the continuous body of fabric comprises: a base component comprising a plurality of courses of non-conductive yarn and a sensing component comprising a first conductive region, the first conductive region comprising at least one course of conductive yarn.

The base component may comprise a stretch yarn. The base component may be arranged to tension the wearable article when worn.

The first conductive region may form a connection terminal for the wearable article.

The wearable article may comprise a plurality of sensing components each comprising a first conductive region comprising at least one course of conductive yarn.

The first conductive regions may each form a connection terminal for the wearable article.

The connection terminals may be arranged proximate to one another.

The wearable article may further comprise a pocket layer attached to the band, wherein a pocket space for receiving an electronics module is formed between the pocket layer and the fabric article. The pocket layer may be integrally formed (integrally knit) with the band.

The first conductive region may form a connection terminal for the wearable article, and wherein the connection terminal is accessible from the pocket space.

The wearable article may further comprise a waterproof layer.

The waterproof layer may be attached to the fabric article.

The first conductive region may be a three-dimensional conductive region that extends away from a surface of the base component.

The sensing component may further comprise a second conductive region.

The second conductive region may be a three-dimensional conductive region that extends away from a surface of the base component.

The first conductive region and the second conductive region may be provided on opposing surfaces of the base component.

The first conductive region may be a three-dimensional conductive region that extends away from a first surface of the base component, and the second conductive region is a three-dimensional conductive region that extends away from a second surface of the base component opposing the first surface.

The first and second conductive regions may be spaced apart from one another along a length of the fabric article, wherein the first and second conductive regions are electrically connected to one another by a conductive pathway.

The sensing component may comprise the conductive pathway.

The wearable article may further comprise a gripper component provided on the first or second surface of the base component.

The sensing component may be a unitary knitted structure formed from a single length of conductive yarn.

The base component may be a double-knit base component. The wearable article may be or may comprise a chest-band, waistband, arm, or wristband. The wearable article may be a bra. The fabric article may form an underband of the bra.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples of the present disclosure will now be described with reference to the accompanying drawings, in which:

FIG. 1 shows a photograph of an example fabric article according to aspects of the present disclosure;

FIG. 2 shows a diagrammatic section view of the fabric article of FIG. 1 ;

FIG. 3 shows a diagrammatic first surface view of the fabric article of FIG. 1 ;

FIG. 4 shows a diagrammatic second surface view of the fabric article of FIG. 1 ;

FIG. 5 shows a diagrammatic section view of the fabric article of FIG. 1 when worn;

FIG. 6 shows a photograph of a first surface of another example fabric article according to aspects of the present disclosure;

FIG. 7 shows a diagrammatic representation of the first surface of the fabric article of FIG. 6 .

FIG. 8 shows a photograph of a second surface of the fabric article of FIG. 6 ;

FIG. 9 shows a diagrammatic representation of the photograph of FIG. 8 ;

FIG. 10 shows a photograph of a second surface of another example fabric article according to aspects of the present disclosure;

FIG. 11 shows a flow diagram for an example method of making a fabric article according to aspects of the present disclosure;

FIG. 12 shows a flow diagram for another example method of making a fabric article according to aspects of the present disclosure;

FIGS. 13 to 15 show knitting notation diagrams for knitting a fabric article according to aspects of the present disclosure using a flat bed knitting machine;

FIG. 16 shows a diagrammatic representation of a plurality of fabric articles according to aspects of the present disclosure made during a single knitting process;

FIG. 17 shows an exploded sectional view of an example wearable assembly comprising fabric article, garment, and electronics module according to aspects of the present disclosure;

FIG. 18 shows an assembled view of the wearable assembly of FIG. 17 ;

FIG. 19 shows an example system according to aspects of the present disclosure;

FIG. 20 shows a schematic diagram for an example electronics module according to aspects of the present disclosure;

FIG. 21 shows an exploded view of another example electronics module according to aspects of the present disclosure;

FIG. 22 shows an exploded view of yet another example electronics module according to aspects of the present disclosure;

FIG. 23 shows the bottom surface of the electronics module of FIG. 22 ; and

FIGS. 24 to 28 show exploded views of example wearable articles incorporating fabric articles according to aspects of the present disclosure.

DETAILED DESCRIPTION

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.

The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the disclosure is provided for illustration purpose only and not for the purpose of limiting the disclosure as defined by the appended claims and their equivalents.

It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

The present disclosure relates to fabric articles. The terms fabric and textile are used interchangeably and are not intended to convey different meanings. The fabric articles may form or be incorporated into a wearable article. “Wearable article” as referred to throughout the present disclosure may refer to any form of article which may be worn by a user such as a smart watch, necklace, bracelet, or glasses. The wearable article may be a garment. The garment may refer to an item of clothing or apparel. The garment may be a top. The top may be a shirt, t-shirt, blouse, sweater, jacket/coat, or vest. The garment may be a dress, brassiere, shorts, pants, arm or leg sleeve, vest, jacket/coat, glove, armband, underwear, headband, hat/cap, collar, wristband, stocking, sock, or shoe, athletic clothing, personal protective equipment, swimwear, wetsuit or drysuit.

The garment may be a tight-fitting garment. Beneficially, a tight-fitting garment helps ensure that the sensor devices of the garment are held in contact with or in the proximity of a skin surface of the wearer. The garment may be a compression garment. The garment may be an athletic garment such as an elastomeric athletic garment.

The fabric articles may be constructed from natural fibres, synthetic fibres, or a natural fibre blended with one or more other materials which can be natural or synthetic. The yarn may be cotton. The cotton may be blended with polyester and/or viscose and/or polyamide according to the particular application. Silk may also be used as the natural fibre. Cellulose, wool, hemp and jute are also natural fibres that may be used in the wearable article. Polyester, polycotton, nylon and viscose are synthetic fibres that may be used in the wearable article.

The fabric articles according to the present disclosure comprise knitted fabric. This contrasts with other fabric constructions such as woven fabrics. Woven and knitted fabrics differ in the way yarns are interwoven or knotted together. A woven fabric is created by interweaving pre-tensioned lengths of yarn horizontally in between threads running vertically. These vertical, or warp threads, wrap themselves around the horizontal, or weft thread, after every course, and are themselves pre-tensioned.

During the manufacture of a woven fabric, all of the yarns running in every direction must be pulled tight at all teams. If the yarns are not tight during knitting, the needles will snag on slacker yarns and break, causing mechanical damage.

Moreover, woven fabrics incorporating conductive yarn are potentially subjected to a change of resistance when stretched apart because, when stretching a woven fabric, the yarns and thus the conductive particles in the yarn will be stretched further apart. This property is undesirable for sensing operations such as for fabric based sensing electrodes.

The present disclosure is directed towards knitted fabrics and, in particular, weft knitted fabrics. In weft knitted fabrics the stitches (or loops) run from left to right horizontally across the fabric. Each horizontal row of stitches is referred to as a course. Weft knitted fabrics can be knit from a single yarn, but in aspects of the present disclosure multiple yarns are used so as to provide different regions of the fabric with different properties. In weft knitted fabrics, a weft thread is pulled through already formed loops of the same thread and is not required taut or under stress from a warp thread. This construction allows for stitches (loops) in the fabric article to deform and alter their shape under stress without stretching the yarn itself. This helps maintain a constant level of electrical resistance.

Warp knitted fabrics are another form of knitted article and can be considered a hybrid between woven and knitted. They are formed using loops, but each column of loops is made from its own thread. Warp knitted threads may allow for more stretch than a woven fabric but are generally not as stretchy as weft knitted fabrics.

Referring to FIGS. 1 to 5 , there is shown a fabric article 100 according to aspects of the present disclosure. The fabric article 100 is an elongate and narrow strip of material. The fabric article 100 is able to be worn so as to obtain measurement signals from the wearer. The fabric article 100 may be used to form a chest strap or wrist strap or may be integrated into a separate wearable article such as a garment. The fabric article 100 may be adhesively bonded to an inner surface of a garment for example.

The fabric article 100 comprises a continuous body of fabric 100. Here, continuous body of fabric 100, refers to a unitary fabric structure that is integrally knit. This means that seams are not provided between different sections of the fabric article 100. In other words, the fabric article 100 is seamless. Although the fabric is seamless, different types of yarns such as conductive and non-conductive yarns are provided in the continuous body of fabric 100. The body of fabric 100 is a weft knitted fabric.

The continuous body of fabric 100 comprises a double-knit non-conductive base component 101. The double-knit non-conductive base component comprises first and second interconnected knit layers. The first knit layer defines first surface 103 and the second knit layer defines second surface 105 opposing the first surface 103. The first surface 103 and the second surface 105 are parallel to one another and spaced apart along the Z axis. In use, the first surface 103 faces towards the skin surface S of the wearer of the fabric article 100 and the second surface 105 faces away from the skin surface S of the wearer. The first surface 103 may be referred to as the back surface 103 and the second surface 105 may be referred to as the front surface 105.

The non-conductive base component 101 is formed from a non-conductive base fabric yarn. In this example, the non-conductive base fabric yarn is a composite fabric elastomeric yarn. In particular, a composite fabric elastomeric yarn comprising 81% nylon and 19% elastane is used. Of course other non-conductive yarns may be used as desired by the skilled person.

The non-conductive base component 101 may comprise additional yarns which may be incorporated during the knitting of the base component 101.

In this example, the base component 101 further comprises additional elastomeric yarn to provide additional stretch in the base component 101. This may improve the comfort of the fabric article 100 and help ensure that an electrode of the fabric article is help in contact with the skin surface S. In this example, elastomeric yarn number 815 by Stretchline Limited is used. The additional elastomeric yarn may not be required if, for example, a high degree of stretch is not desired or the base fabric yarn already as the desired degree of stretch.

In this example, the base component 101 further comprises a sealing/bonding yarn to seal the edges of the fabric article 100 to reduce and even prevent fraying of the fabric article. An example sealing/bonding yarn is the Porte yarn from Nittobo Group of Japan. The present disclosure is not limited to this example, and other sealing/bonding yarns are within the scope of the present disclosure.

The continuous body of fabric 100 further comprises a sensing component 107. This means that the sensing component 107 is integrally formed with the base component 101. The sensing component 107 is formed from conductive yarn, and in particularly is a unitary knitted structure formed from a single length of conductive yarn. This means that separate wires, connectors or other hardware elements are not required to electrically connect the different parts of the sensing component 107 together. In this example, Circuitex™ conductive yarn from Noble Biomaterials Limited is used to form the sensing component 107. Of course, other conductive yarns may be used. The conductive yarn may comprise a non-conductive or less conductive base yarn which is coated or embedded with conductive material such as carbon, copper and silver. The conductive yarn may be a stainless-steel yarn such as those manufactured by TIBTECH Innovations.

The sensing component 107 comprises a first conductive region 109. The first conductive region 109 is provided on the first surface 103 and extends along part of the length of the fabric article 100 in the direction of the Y-axis. The first conductive region 109 is a three-dimensional conductive region 109 that extends away from the first surface 103 along the Z-axis. This three-dimensional/raised conductive region 109 forms a three-dimensional/raised electrode 109 for contacting the skin surface S of the wearer to measure signals from the wearer and/or introduce signals into the wearer. The first conductive region 109 comprises a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the knit layer defining the first surface 103 of the base component 101. The remaining courses of conductive yarn extend away from the first surface 103 of the base component 101 to form the raised conductive region 109.

The electrode 109 may be arranged to measure one or more biosignals of a user wearing the fabric article 100. Here, “biosignal” may refer to any signal in a living being that can be measured and monitored. The electrode 109 is generally for performing bioelectrical or bioimpedance measurements. Bioelectrical measurements include electrocardiograms (ECG), electrogastrograms (EGG), electroencephalograms (EEG), and electromyography (EMG). Bioimpedance measurements include plethysmography (e.g., for respiration), body composition (e.g., hydration, fat, etc.), and electroimpedance tomography (EIT). The electrode 109 may additionally or separately be used to apply an electrical signal to the wearer. This may be used in medical treatment or therapy applications.

The sensing component 107 further comprises a second conductive region 111. The second conductive region 111 is provided on the second surface 105 and extends along part of the length of the fabric article 100 along the Y-axis. The second conductive region 111 is a three-dimensional conductive region 111 that extends away from the second surface 105 along the Z axis. The second conductive region 111 forms a connection terminal 111 for electrically connecting with an electronics module 200. In particular, a conductive interface element 201 of the electronics module 200 is able to contact the connection terminal 111 to electrically connect the electronics module 200 to the connection terminal 111. The second conductive region 119 comprises a plurality of courses of conductive yarn. Opposing end courses of the conductive yarn are interconnected with the knit layer defining the second surface 105 of the base component 101. The remaining courses of conductive yarn extend away from the second surface 105 of the base component 101 to form the raised conductive region 111.

The first conductive region 109 and the second conductive region 111 are spaced apart from one another along the length of the fabric article 100. That is, they are spaced apart along the Y-axis (FIGS. 2 to 5 ).

The sensing component 107 further comprises a conductive pathway 113. The conductive pathway 113 extends along the length of the fabric article 100 between the first conductive region 109 and the second conductive region 111 to electrically connect the first conductive region 109 to the second conductive region 111. The conductive pathway 113 is substantially flush with the first surface 103 of the base component 101 and is formed from one or more (two in this example) of courses of conductive yarn extending between adjacent courses of non-conductive yarn in the base component 101. Proximate to the second conductive region 111, part of the conductive yarn 123 extends through the base component 101 so as to be electrically connected to the second conductive region 111. The conductive pathway 113 thus electrically connects the raised electrode 109 and the connection terminal 111 on opposing surfaces of the base component 101. The conductive pathway 113 is not required to extend along the first surface 103 of the base component 101 and may instead extend along the second surface 105. Proximate to the first conductive region 109, part of the conductive yarn 123 can extend through the base component 101 so as to be electrically connected to the first conductive region 109.

Beneficially, the fabric article 100 of the present disclosure comprises a non-conductive base component 101 knit using both needle beds of the knitting machine. This double-faced base component 101 has two layers of fabric that are knit together as they are formed. The resultant base component 101 has two knit sides that are interlocked together. One or more conductive regions 109, 111 are provided on or extending from either of the exposed surfaces 103, 105 of the double-knit base component 101. These conductive regions are able to be formed during the knitting operation for forming the base component 101 through selective use of the needle beds of the knitting machine. Thus, the conductive regions 109, 111 are integrally knit with the base component 101.

A fabric article 100 that can be manufactured integrally in a single knitting operation is therefore provided. This means that discrete electronic components do not need to be integrated into an already formed base component but instead the sensing component is formed of conductive yarn as the base component 101 is being knitted. The resultant fabric article 100 has a singular fabric structure which handles, feels, behaves and looks like a fabric while providing the desired sensing functionality.

The fabric article 100 is made using a flat-bed knitting machine that has a front bed of needles and a back bed of needles. Additional beds of needles may be provided and used in the knitting process. Other knitting machines capable such as circular knitting machines may also be used to manufacture the fabric article 100 generally the knitting machines are required to have at least first and second beds of needles.

The raised electrode 109 extends along the Z axis for a greater amount than the conductive pathway 113 such that the raised electrode 109 is thicker than the conductive pathway 113. Having a raised electrode 109 that extends above the conductive pathway 113 is beneficial in improving electrode contact with the skin surface S particularly when the wearer is moving. Having a thinner conductive pathway 113 is also beneficial in terms of improving comfort and minimising the visual appearance of the sensing component 107 on the fabric article 100. This is particularly important when an insulating bonding layer is applied to the conductive pathway 113. Insulating bonding layers are typically applied to prevent the conductive pathway 113 from forming a conductive connection with the skin surface S of the wearer when worn. If the conductive pathway 113 is too thick, then the insulating bonding layer may protrude above the electrode 109 and push the electrode 109 away from the skin surface S.

The connection terminal 111 extends along the Z axis away from the second surface 105 to form a raised connection terminal 111. Having a raised connection terminal 111 is beneficial in terms of improving the electrical connection between the connection terminal 111 and the interface element 201 of the electronics module 200.

The electrode 109 is wider along the X axis than the conductive pathway 113. Having a wider electrode 109 is beneficial in providing increased surface area of electrode 109 contact with the skin surface S. Having a narrower conductive pathway 113 is beneficial in terms of improving comfort for the wearer and minimising the visual appearance of the sensing component 107 on the fabric article 100. The connection terminal 111 is also wider along the X axis than the conductive pathway 113. Having a wider connection terminal 111 is beneficial in terms of improving the electrical connection between the connection terminal 111 and the interface element 201 of the electronics module 200.

The conductive pathway 113 is longer along the Y axis than the electrode 109 and the connection terminal 111. This is beneficial for spacing the electrode 109 away from the connection terminal 111.

The electrode 109 is longer and wider than the connection terminal 111, but this is not required in all examples. The electrode 109 and the connection terminal 111 may have the same or similar dimensions. The particular dimensions will depend on factors such as the desired position of the electrode 109 on the skin surface S and the type and construction of the electronics module 200 and interface element 201.

The construction of fabric article 100 in FIGS. 1 to 5 provides the electrode 109 and connection terminal 111 on opposed surfaces 103, 105 of the base component 101. This is not required in all examples of the present disclosure as, in some examples, the electrode 109 and the connection terminal 111 may be provided on the same surface of the base component 101. However., the arrangement of FIGS. 1 to 5 is preferred as it enables an electronics module 200 to be connected to the electrode 109 from the second, outer surface 105 without additional modification to the fabric article 100.

If the connection terminal and the electrode were both located on a first surface then additional manufacturing steps may be required to enable an electronics module located on the second surface to extend through the hole to connect with the connection terminal. For example, a hole may have to be formed in the fabric article. Forming the hole may require additional manufacturing steps which may increase the time and cost of manufacturing the fabric article. Moreover, the hole may weaken the structural integrity of the fabric article. In another example, a conductive fastener such as a conductive metal stud may be inserted into the base component to allow the interface element to connect with the connection terminal on the first surface. Incorporating additional hardware into the fabric article may increase the manufacturing costs and reduce the comfort and visual appearance of the fabric article.

The first conductive region 109 and the second conductive region 111 further comprise a filler material disposed therein. The filler material is integral with the continuous body of fabric and in particular comprises an expanding yarn. During the knitting operation for forming the continuous body of fabric, the expanding yarn is intruded into the conductive regions 109, 111 such that it is provided in the space between the conductive regions 109, 111 and the base component 101. The expanding yarn used in this example is a Newlife ^(TM) polyester filament yarn manufactured by Sinterama S.p.A.

Beneficially, the filler material raises the profile of the conductive regions 109, 111 away from the base component 101. This helps to increase the quality, consistency and area of contact area. This is particularly beneficial for the raised electrode 109 as it helps ensure contact against the skin surface S without requiring the fabric article 100 to provide additional compression such as through additional elastomeric material. The filler material maintains the shape of the raised conductive regions 109,111 and protects against deformation, buckle and roll even when they are rubbed against the skin or other surface. Moreover, using an expanding yarn means that the process of filling out the conductive regions 109, 111 is an intrinsic part of the manufacturing process. A separate manual process of inserting filler material into already formed conductive regions 109, 111 is not required.

While the above examples refer to double-knit base components. The present disclosure is not limited to such examples. The base component may have a single bed structure, a links structure, or a ribbed structure for example.

Fabric article 100 may be attached to a wearable article such as a garment.

Fabric article 100 may be integrally knit with the wearable article. Such as by integrally knitting a garment comprising the fabric article 100.

The present disclosure is not limited to any particular dimension of the electrode 109, conductive pathway 113, and connection terminal 111.

Generally, however, the electrode 109, the conductive pathway 113, and connection terminal 111 extend for a height of between 0.2 mm and 30 mm along the Z-axis.

The electrode 109, conductive pathway 113, and connection terminal 111 extend for a width of at least 0.1 mm along the X axis. The electrode 109 and/or connection terminal 111 and/or conductive pathway 113 may extend for a width of at least 0.5 mm, at least 1 mm, at least 2 mm, or at least 3 mm. The electrode 109 and/or connection terminal 111 may have a width of at least 3 mm, at least 5 mm, at least 10 mm, at least 15 mm, at least 20 mm, or at least 50 mm. The electrode 109 and/or connection terminal 111 may have a width between 5 mm and 20 mm.

The electrode 109, conductive pathway 113, and connection terminal 111 extend for a length of at least 1 mm along the Y axis. The electrode 109 may have a length of at least 5 mm, at least 10 mm, at least 20 mm, at least 50 mm, or at least 100 mm. The electrode 109 may have a length of between 20 and 50 mm. The connection terminal 111 may have a length of at least 5 mm, at least 10 mm, at least 20 mm, at least 50 mm, or at least 100 mm. The connection terminal 111 may have a length of between 5 mm and 10 mm. The conductive pathway 113 may extend for a least of at least 5 mm, at least 10 mm, at least 20 mm, at least 50 mm, at least 100 mm, at least 200 mm, at least 300 mm, at least 500 mm. The conductive pathway 113 may extend for a length of the between 100 mm and 300 mm.

Referring to FIGS. 6 to 9 , there is shown another example fabric article 100 according to aspects of the present disclosure. The fabric article 100 comprises a continuous body of fabric 100. That is, the fabric article 100 is a knitted component of a unitary construction. The fabric article comprises a base component 101 and a pair of sensing components 107 a, 107 b.

Unlike the example of FIGS. 1 to 5 , the electrodes 109 a, 109 b and the connection terminals 111 a, 111 b, are both provided on the first surface 103 of the base component 101. Holes 129 a, 129 b are formed in the connection terminals 111 a, 111 b / first non-conductive knit layer 125. These holes 129 a, 129 b may help interface elements of an electronics module to be retained in place and electrically connect with connection terminals 111 a, 111 b. These holes 129 a, 129 b are not required in all aspects of the present disclosure.

The second non-conductive knit layer 127 comprises indentations 131 a, 131 b. These indentations are formed by voids 131 a, 131 b in the second non-conductive knit layer 127 that expose the first non-conductive knit layer 125. These indentations 131 a, 131 b can seat the interface elements of the electronics module and may reduce the amount the electronics module protrudes outwardly from the second surface 105 when mounted on the fabric article 100. Moreover, the indentations 131 a, 131 b may assist in bringing the interface elements of the electronics module into conductive connection with the connection terminals 111 a, 111 b provided on the first surface 103. The indentations 131 a, 131 b are formed by changing from a double-knit base component fabric into a single-knit (single bed) based component fabric in the desired area/region.

Conductive pathways 113 a, 113 b extend from the raised conductive regions 109 a, 109 b to the raised conductive regions 111 a, 111 b. The conductive pathways 113 a, 113 b each comprise one or a plurality of courses of conductive yarn. The conductive pathways 113 a, 113 b are narrower than the conductive regions 109 a, 109 b, 111 a, 111 b and do not extend substantially above the base component 101.

FIG. 10 shows a variation of the fabric article 100 of FIGS. 6 to 9 . In this example, a pocket 133 is integrally knit with the base component 101 and in particular forms part of the second non-conductive knit layer 127. The pocket 133 has opening which enables access inside the pocket 133. The electronics module may be inserted into and removed from the pocket 133.

When positioned in the pocket 133, the interface elements are brought into conductive connection with the connection terminals 111 a, 111 b.

Referring to FIG. 11 , there is shown a method of manufacturing a fabric article according to aspects of the present disclosure. Step S101 of the method comprises forming a continuous body of fabric comprising a base component and a sensing component comprising a first conductive region. The fabric article is manufactured in a continuous process using a knitting machine comprising a first bed of needles and a second bed of needles. Preferably, the knitting machine is a flat bed knitting machine.

Referring to FIG. 12 , there is shown a detailed example of the steps involved in forming a continuous body of fabric according to aspects of the present disclosure. Step S201 of the method comprises knitting, using first and second beds of the knitting machine, non-conductive yarn to form the double-knit base component. Step S202 of the method comprises knitting, using only the first bed, conductive yarn to form the first conductive region. Steps S201 and S202 may not be discrete process steps performed separately and may be performed at least partially at the same time.

In preferred examples, step S202 comprises knitting, using only the first bed, a plurality of courses of conductive yarn to form a three-dimensional first conductive region that extends away from a surface of the base component.

In some examples, forming the continuous body of fabric further comprises forming a second conductive region of the sensing component. If the second conductive region is to be formed on the same surface as the first conductive region (e.g. as per the examples of FIGS. 6 to 9 ) then this will comprise knitting, using the first bed only, conductive yarn to form the second conductive region. Otherwise, if the second conductive region is to be formed on the opposing surface to the first conductive region (e.g. as per the examples of FIGS. 1 to 5 ) then this will comprise knitting, using the second bed only, conductive yarn to form the second conductive region. The second conductive region may be a raised region extending away from the base component. This raised region can be achieved by knitting a plurality of courses of conductive yarn.

In some examples, forming the continuous body of fabric further comprises forming a conductive pathway that extends between and electrically connects the first conductive region to the second conductive region. The conductive pathway may be formed by using the first bed only to knit conductive yarn extending along the surface of the base component from the first conductive region to the second conductive region. In examples, where the first and second conductive regions are formed on opposing surfaces of the base component, the second bed may be used to pull the conductive yarn to the other surface of the base component.

A more detailed example knitting operation for forming a fabric article according to aspects of the present disclosure will now be described. This knitting operation is performed by knitting a plurality of courses which extend along the length of the continuous body of fabric (the Y-axis in FIGS. 1 to 11 ). The knitting operation is performed using a flat bed knitting machine comprising first and second needle beds. The knitting operation involves knitting non-conductive and conductive yarn. The different yarns are fed using different yarn carries of the knitting machine.

Initially, the first and second needle beds are used to knit a plurality of courses of non-conductive yarn to form part of the base component. The plurality of courses extend along the length of the continuous body of fabric. Since the first and second needle beds are used together to perform the knitting, the base component has a double-knit structure.

The first bed, only, is then used to knit a plurality of courses of conductive yarn. This forms part of the first conductive region. These courses of conductive yarn extend along part of the length of the continuous body of fabric and are integrally knit with the base component. Since the knitting operation is performed using the first bed only, the courses of conductive yarn extend from the first surface of the double-knit structure.

The last course of conductive yarn is continued along the Y-axis so that it extends from the end of the first conductive region to the beginning of the to-be-formed second conductive region. This forms part of the conductive pathway.

The second bed is used to pull/transfer the conductive yarn to the second surface of the base component. A plurality of courses of conductive yarn are then knit using the second bed only to form part of the second conductive region. The plurality of courses extend along part of the length of the fabric article. The first and second conductive regions are on opposing surfaces of the base component, spaced apart from one another along the Y axis and electrically connected by the conductive pathway.

The fist bed is used to transfer/pull the conductive yarn back to the first surface of the base component. The first bed then knits a course of conductive yarn to form the remaining part of the conductive pathway. The first bed continues knitting a plurality of courses to form the remaining part of the first conductive region.

Then, the first and second beds are used together to knit the remaining plurality of courses of the base component.

FIGS. 13 to 15 show a flat-bed needle notation diagram for forming a fabric article according to aspects of the present disclosure. The needle notation diagram is a compressed diagram used for the purposes of illustration. The conductive regions, for example, are scalable/repeatable depending on the size of the desired fabric article or the functional need. The needle notation diagram shows the knitting operation performed by a flat-bed knitting machine in order to manufacture the fabric article. An example flat-bed knitting machine comprises first and second needle beds which each comprise the same number of needles arranged along horizontal lines. The needles are controlled by needle cams. The needles are controlled to knit loops otherwise known as stitches to form the fabric article 100. The knitting machine may have additional needle beds if desired and as known in the art.

The knitting operation comprises a plurality of steps starting at S301 (bottom of FIG. 13 ). In each step, the knitting operations performed by the front bed (A) and the rear bed (B) are shown. The numbers “3”, “4”, “5”, “6”, “7” at the sides of each step denotes the yarn carrier that is used in the knitting step. The position of the number denotes the position of the yarn carrier after the completion of the course direction. A number at the right-side means that the knitting operation is performed from left to right and finished at the right side whereas a number at the left-side means that the knitting operation is performed from right to left and finishes at the left side.

The knitting machine in this example has five yarn carriers each carrying a different type of yarn.

The yarn carries are as follows:

-   Yarn carrier 3—non-conductive base fabric yarn. -   Yarn carrier 4—elastomeric yarn. -   Yarn carrier 5—conductive yarn. -   Yarn carrier 6—expanding yarn. -   Yarn carrier 7—sealing/bonding yarn.

The method of manufacturing the fabric article 100 begins at step S301 at the bottom of FIG. 13 .

In step S301, the front and back needle beds (A), (B) are used simultaneously to knit a course of base yarn using yarn carrier 3. The knitting direction is from left to right. The course comprises front and back knit layers which are interconnected.

In step S302, front bed (A) only is used to knit a course of elastomeric yarn using yarn carrier 4. The knitting direction is from left to right. This operation introduces a course of elastomeric yarn into the front layer of the base component.

In step S303, back bed (B) only is used to knit a course of elastomeric yarn using yarn carrier 4.

The knitting direction is from right to left. This operation introduces a course of elastomeric yarn into the back layer of the base component. This course of elastomeric yarn balances out the appearance of the base component following the introduction of the course of elastomeric yarn in the front layer in step S302.

In step S304, the front and back needle beds (A), (B) are used simultaneously to knit a course of base yarn using yarn carrier 3. The knitting direction is from right to left. The course comprises front and back knit layers which are interconnected. In step S305, front bed (A) only is used to knit a course of elastomeric yarn using yarn carrier 4. The knitting direction is from left to right. This operation introduces a course of elastomeric yarn into the front layer of the base component. Further, in step S306, back bed (B) only is used to knit a course of elastomeric yarn using yarn carrier 4. The knitting direction is from right to left. This operation introduces a course of elastomeric yarn into the back layer of the base component.

Steps S304 to S306 may be repeated any number of times to form a plurality of courses of the base component. The plurality of courses comprising the base fabric yarn and the elastomeric yarn. The greater the number of courses, the wider the fabric article 100 in the X direction.

In step S307, the front and back needle beds (A), (B) are used simultaneously to knit a course of base yarn using yarn carrier 3. The knitting direction is from left to right. The course comprises front and back knit layers which are interconnected. In step S308, front bed (A) only is used to knit a course of elastomeric yarn using yarn carrier 4. The knitting direction is from left to right. This operation introduces a course of elastomeric yarn into the front layer of the base component. Further, in step S309, back bed (B) only is used to knit a course of elastomeric yarn using yarn carrier 4. The knitting direction is from right to left. This operation introduces a course of elastomeric yarn into the back layer of the base component.

In step S310, the front and back needle beds (A), (B) are used simultaneously to knit a course of base yarn using yarn carrier 3. The knitting direction is from right to left. The course comprises front and back knit layers which are interconnected.

In steps S311 to 316 (starting at the bottom of FIG. 14 ), back needle bed (B) only is used to knit a plurality of courses (six in this example) of conductive yarn using yarn carrier 5. The number of courses can be any number greater than or equal to one. Even with a limited number of courses, the 3D profile of the conductive region can still be provided by introducing the expanding yarn. The knitting direction alternates from left to right and right to left. This knitting operation forms part of the first conductive region of the fabric article which extends from the first surface of the base component. The first surface of the base component is the back surface in this example. Because the conductive yarn is knitted using one bed (B) only, the opposite bed of needles (A) is not able to balance out the knit layers. This causes the conductive yarn to bunch-up to create a three-dimensional structure. This three-dimensional structure may form an elongate tubular shape.

In step S317, back needle bed (B) only is used to knit another course for the first conductive region using yarn carrier 5. The knitting direction is from left to right. The knitted course continues to form part of the conductive pathway. The conductive pathway extends along the Y axis from the end of the first conductive region (C) to the beginning of the to-be-formed second conductive region (D). The conductive pathway is knit using alternate back knit and float knit operations. In a float knit operation, a stitch is not formed, and instead the yarn floats over to the next chosen needle. Continuing in step S317, the front needle bed (A) only is used to knit the conductive yarn to form the first course of the second conductive region. The second conductive region extends from the front surface of the base component. This means that the front needle bed (A) pulls the conductive yarn through the base component.

In steps S318 to S319, the front needle bed (A) only is used to knit a plurality of courses (two in this example) of conductive yarn using yarn carrier 5. The knitting direction alternates from right to left and left to right. Because the conductive yarn is knitted using one bed (A) only, the opposite bed of needles (B) is not able to balance out the knit layers. This causes the conductive yarn to bunch-up to create a three-dimensional structure. This three-dimensional structure may form an elongate tubular shape

In steps S320 to S323, front and back needle beds (A) and (B) are used to insert expanding yarn using yarn carrier 6. The knitting direction alternates from left to right and right to left. The expanding yarn is used to fill out and add shape to the first conductive region. The expanding yarn is knit using a combination of front and back float and tuck knitting operations. Tuck knitting operations result in the formation of an extra stitch behind an existing stitch. The extra stitch is not visible from the outside surface of the fabric article. The tuck stitch is used to layer-in the expanding yarn behind the first conductive region so that it is not visible from the outside of the fabric article.

While in this example, the knitting of the expanding yarn uses both the front and back needle beds (A) and (B), this is not required in all examples. The expanding yarn may be knit using tuck and float stitches on the front needle bed (A) only. This can be beneficial as it anchors the expanding yarn on the base component rather than the conductive yarn region which is knit on the back bed (5). In this way, when the expanding yarn expands it pushes against the conductive yarn to urge the conductive yarn away from the base component.

In this example, expanding yarn is not used to fill out the second conductive region, but this may also be performed if desired. In addition, expanding yarn may be used to fill out the conductive pathway if desired. The expanding yarn can be knit using the back bed (B) in regions where the conductive yarn is knit using the front bed (A) and vice versa. As explained above, this helps ensure that the expanding yarn pushes against and urges the conductive yarn regions away from the base component.

In steps S324 to S325, the front needle bed (A) only is used to knit a plurality of courses (two in this example) of conductive yarn using yarn carrier 5. The knitting direction alternates from right to left and left to right. These operations continue the formation of the second conductive region.

In step S326, the front needle bed (A) only is used to knit a course of conductive yarn using yarn carrier 5. The knitting direction is from right to left. This course is the final course for the second conductive region. The back needle bed (B) is used to pull the conductive yarn to the front surface of the base component and knit the final course of the conductive pathway and a further course for the first conductive region. The final course of the conductive pathway is also knit using alternate back knit and float knit operations. This effectively fills in the gaps in the earlier knit course of the conductive pathway which means that the final conductive pathway is formed from only one course of conductive yarn.

In steps S327 to S332, back needle bed (B) only is used to knit a plurality of courses of conductive yarn using yarn carrier 5. This forms the remaining plurality (six in this example) of courses of the first conductive region using yarn carrier 5.

Steps S333 to S341 are a repetition of steps 301 to 309 and result in the formation of additional courses of base component using base fabric and elastomeric yarns. Step S342 knits a final course of base fabric yarn using front and back needle beds simultaneously.

In step S343, all of the stitches are transferred from the back bed (B) to the front bed (A).

In steps S344 to S345, front needle bed (A) only knits a plurality of courses (two in this example) of sealing/bonding yarn using yarn carrier 7. The knitting direction alternates from left to right and then right to left.

In steps S346 to S347, front needle bed (A) only knits a plurality of courses (two in this example) of base fabric yarn using yarn carrier 3. These courses hold down the sealing/bonding yarn introduced in steps S344 to S345. The knitting direction alternates from left to right and then right to left.

It will be appreciated that steps S301 to S347 may be repeated a number of times to form a plurality of fabric articles which are interconnected together. FIG. 16 shows an example of this. In FIG. 16 a plurality of fabric articles 100 (six in this example) are manufactured in one go during a knitting operation. This continuous body of fabric may be separated along the edges 135 to separate the individual fabric articles 100. Beneficially, by providing the sealing/bonding yarn, the edges 135 do not fray as a result of being separated.

Additionally or separately to using a sealing/bonding yarn, the method may comprise overlocking or plain stitching the end of a conductive region to physically bind/stitch the fabric together. Additionally or separately still, a bind off knitting technique may be used to seal the fabric and stop it from running or unroving.

The separation processing may be facilitated by knitting drawthread into the base component. An example draw thread is provided SOMAC Threads LTD. The method comprises knitting one or more courses of drawthread followed by a sequence of knitted courses that are used to set up the subsequent fabric article to be knitted during the manufacturing process. In flat-bed knitting, it is conventional to knit a plurality of courses to set up each subsequent item in a production run or continuous batch of items.

In this example, the sequence uses yarn carrier 4 to knit, in sequence: a course of all-needle knit, a course of front bed knitting only, a course of back bed knitting only, and another course of front bed knitting only. These 4 rows are normally referred to as ‘set-up’ courses and are conventionally used to proceed knitted articles during a flat bed knitting process.

The process of separating may comprise manually pulling the draw thread to remove it from the continuous body of fabric. Drawthread is made to behave in a slippery and non-abrasive manner in order to facilitate easy pull and removal. Alternatively, a particular type of drawthread may be selected to melt upon application of steam. An example of melting drawthread is FILAC yarn by SOMAC Threads LTD. In this way, when steam is applied to the continuous body of fabric to seal the sealing/bonding yarn, the drawthread can dissolve at the same time, automatically separating the individual strips of fabric article.

The base yarn is not required to be knit using the techniques described in the above example.

For example, the base yarn may be knit using an interlocked knitting technique. An example of interlocked knitting comprises: knitting a first course of yarn using the even needles on the front needle-bed and the odd needles on the back needle-bed; knitting a second course of yarn using both the odd and even needles on the front and back needle-beds; and knitting a third course of yarn using the odd needles on the front needle-bed and the even needles on the back needle-bed. Of course, the order may be altered such that the odd needles on the front needle-bed and even needles on the back needle-bed are used first. An interlocked technique provides additional stretch for the fabric article and especially helps the fabric article to stretch and return to its original shape.

For example, the base yarn may be knit using tuck-rib stitches which are formed using tuck stitches on one needle bed complemented by knitting stitches on the other needle bed. The stitches may be knitted in a two-course repeat manner. The tuck-rib stitches are often referred to as cardigan stitches.

The tuck stitches cause the rib wales to gape apart so that the body width spreads outwards to a greater extent than the rib border this results in larger gaps between the stitches.

The cardigan stitches may be half-cardigan stitches. Half-cardigan stitches use repeated pairs of knitted courses. The first course has knitted loops on both the front and back needle beds.

The second course has tuck stitches on one of the needle beds and knitted loops on the other needle bed.

The cardigan stitches may be full-cardigan stitches. Full-cardigan stitches use repeating pairs of knit courses where the second course in each pair uses the reverse of the stitches used for the first course in each pair. The first and second courses both use tuck stitches on one needle bed and knitted loops on the other needle bed.

In an example full-cardigan operation, a first course comprises knitted loops on the front needle bed and tuck stitches on the back bed. A second course is knit using the reverse of the sequence used to knit the first course and has tuck stitches on the front bed and knitted loops on the back bed. Subsequent knit courses are a repetition of the first and second courses.

Advantageously, knitting the base component using cardigan stitches means that the base component has larger gaps between stitches as compared to other knitting techniques such as just using knitted loops on both needle beds or an interlock knitting technique. These larger gaps enable the base component to accommodate thicker conductive yarn. Thicker conductive yarn is advantageous as it is less likely to break and is more resistant to washing. Fabric articles with thicker conductive yarn can typically be washed a greater number of times without the measured impedance increasing beyond and acceptable value.

Yarn thickness may be measured using its yarn count. Yarn count is a measure of the total length per weight of yarn. The yarn count measures include Cotton Count (cc) which gives a measure of the number of 840 yard units in a pound of yarn, Worsted Count (wc) which gives a measure of the number of 560 yard units in a pound of yarn, and Numero Metric Count (nm) which gives a measure of the number of 1000 metre units in a kilogram of yarn.

Yarn counts are typically represented in the form X/Y, where X is the yarn count for a single ply of yarn and Y is the number of piles that make up the yarn. The number X is divided by Y to give the final yarn count.

For example, a yarn may have a yarn count of 30/2 nm which means that each ply has a yarn count of 30 and that there are two plies that make up the yarn. The final yarn count is 15 nm which means that there are 15000 metres of yarn per kilogram.

Another yarn may have a yarn count of 20/2 nm which means that each ply has a yarn count of 20 and that there are two plies that make up the yarn. The final yarn count is 10 nm which means that there are 10000 metres of yarn per kilogram.

A yarn with a lower yarn count in nm is therefore heavier per unit length and thicker than a yarn with a higher yarn count.

In some examples, a yarn with a yarn count of 15 nm or higher is thin enough that it can fit through the gaps in a base component regardless of the knitting technique used to manufacture the base component, e.g. knit using both needle beds simultaneously or using an interlock technique. However, yarns with yarn counts lower than this value may be more challenging to fit through the gaps between stitches in the base component. This can increase the complexity of the knitting process and reduce the appearance and performance of the resultantly formed fabric article.

Advantageously, knitting the base component using cardigan stitches results in larger gaps between the knitted stitches which allows for conductive yarns with a yarn count of less than 15 nm to be intermeshed with the base component.

Moreover, using cardigan stitches result in a base component with a reduced weight as cardigan stitches use less yarn and are lighter than other knit structures. This enables a wider base component to be knitted for the same weight/amount of yarn. Moreover, the knitting process for forming a base component using cardigan stitches is faster than other knitting techniques such as interlock which enables the fabric article to be manufactured more quickly. Therefore, forming the base component using cardigan stitches reduces the time required to knit the fabric article.

In preferred examples, the base component is knit using cardigan stitches and the conductive yarn has a yarn count of less than 15 nm. The yarn count may be less than 14 nm, less than 13 nm, less than 12 nm, less than 11 nm. The yarn count may be greater than 5 nm, greater than 6 nm, greater than 7 nm, greater than 8 nm, or greater than 9 nm. The yarn count may be between 8 nm and 12 nm and is preferably 10 nm (e.g. a yarn with a yarn count of 20/2 nm). The conductive yarn in this example is preferably a stainless-steel yarn.

In preferred examples, full-cardigan rather than half-cardigan stitches are used. This is because half-cardigan stitches have an unbalanced structure with a different appearance on each side of the fabric. Full-cardigan stitches have a balanced structure with the same appearance on both sides of the fabric. A balanced structure can be considered more aesthetically pleasing.

It will be appreciated that not all of the stitches used to form the base component are required to be cardigan stitches to achieve the effect of having larger knitted loops. For example, a course of knitting using both needle beds can be performed immediately before and after knitting the conductive yarn. The effect of larger knitting loops is still achieved by the cardigan stitches used for the rest of the base component. Referring to FIGS. 17 and 18 , there is shown an example wearable assembly 10 according to aspects of the present disclosure. The wearable assembly 10 comprises a pair of fabric articles 100 a, 100 b, an electronics module 200 and a garment 300.

The garment 300 comprises an outer layer 301 and an inner layer 307. The inner layer 307 is proximate to the skin surface S when worn. The garment 300 further comprises a pocket 305 extending from an external surface of the outer layer 301.

The fabric assembly 100 a, 100 b is disposed between the outer layer 301 and the inner layer 307. The first surface 103 a, 103 b of the fabric assembly 100 a, 100 b is attached to the internal surface of the outer garment layer 301. The second surface 105 a, 105 b of the fabric assembly 100 a, 100 b is attached to the inner layer 307. Adhesive layers (not shown) may be provided to form the attachment of the fabric assembly 100 a, 100 b to the outer garment layer 301 and inner garment layer 307.

The inner garment layer 307 covers the electrically conductive pathway 113 a to prevent the electrically conductive pathway 113 a from forming a conductive connection with the skin surface. The inner garment 307 may not cover the entirety of the fabric articles 100 a, 100 b or the entirety of the outer layer 301 of the garment. The inner garment 307 may be in the form of a panel. The inner garment layer 307 may be an insulating bonding layer.

The outer layer 301 has a pair of openings 303 a, 303 b that are aligned with the connection terminals 111 a, 111 b of the fabric articles 100 a, 100 b. The connection terminals 111 a, 111 b may extend at least partially into the openings 303 a, 303 b. The openings are covered by the pocket 305.

The electronics module 200 is removably received within pocket 305. When positioned in the pocket 305, the interface elements 201 a, 201 b are able to extend at least partially into the openings 303 a, 303 b to conductively connect with the connection terminals 111 a, 111 b.

In the example of FIGS. 17 and 18 , the pocket 305 is a bonded pocket 305. This is not required. The pocket 305 may be stitched into the outer layer of the garment 301 or may be integrally formed with the outer layer of the garment 301.

In the example of FIGS. 17 and 18 , two separate fabric articles 100 a, 100 b are provided. However, a single fabric article 100 comprising two sensing components 107 a, 107 b may also be used. That is, the fabric articles 100 a, 100 b may be connected together or formed from the same continuous body of fabric.

Referring to FIG. 19 , there is shown an example system 1 according to aspects of the present disclosure. The system 1 comprises wearable assembly 10 and a mobile device 500.

The wearable assembly 10 comprises a garment 300. The outer garment layer 301 is visible in

FIG. 19 . One or more fabric articles in accordance with aspects of the present disclosure are provided in the garment 300 so as to enable the wearable assembly 10 to perform a sensing function. The fabric articles may be integrally formed with the garment 300. For example, the fabric articles may be integrally knit with the garment 300. Alternatively, the fabric articles may be attached to the garment such as by being bonded to an inside surface of the outer garment layer 301 as shown in FIGS. 17 and 18 .

The electronics module 200 is able to be disposed within the pocket 305. When positioned within the pocket 200, the electronics module 200 is able to integrate with one or more sensing components of the fabric articles so as to obtain signals from the sensing components. The electronics module 200 is further arranged to wirelessly communicate data to the mobile device 500. Various protocols enable wireless communication between the electronics module 200 and the mobile device 500. Example communication protocols include Bluetooth®, Bluetooth® Low Energy, and near-field communication (NFC).

The present disclosure is not limited to electronics modules 200 that communicate with mobile devices 500 and instead may communicate with any electronic device capable of communicating directly with the electronics module 200 or indirectly via a server over a wired or wireless communication network. The electronic device may be a wireless device or a wired device. The wireless/wired device may be a mobile phone, tablet computer, gaming system, MP3 player, point-of-sale device, or wearable device such as a smart watch. A wireless device is intended to encompass any compatible mobile technology computing device that connects to a wireless communication network, such as mobile phones, mobile equipment, mobile stations, user equipment, cellular phones, smartphones, handsets or the like, wireless dongles or other mobile computing devices. The wireless communication network is intended to encompass any type of wireless network such as mobile/cellular networks used to provide mobile phone services.

The present disclosure is not limited to the use of pockets 305 for releasably mechanically coupling the electronics module 200 to the garment 300 and other mounting arrangements for the electronics module 200 are within the scope of the present disclosure. The mechanical coupling of the electronic module 200 to the garment 300 may be provided by a mechanical interface such as a clip, a plug and socket arrangement, etc. The mechanical coupling or mechanical interface may be configured to maintain the electronic module 200 in a particular orientation with respect to the garment 300 when the electronic module 200 is coupled to the garment 300. This may be beneficial in ensuring that the electronic module 200 is securely held in place with respect to the garment 300 and/or that any electronic coupling of the electronic module 200 and the garment 300 (or a component of the garment 300) can be optimized. The mechanical coupling may be maintained using friction or using a positively engaging mechanism, for example.

Beneficially, the removable electronic module 200 may contain all of the components required for data transmission and processing such that the garment 300 only comprises the sensing components. In this way, manufacture of the garment 300 may be simplified. In addition, it may be easier to clean a garment 300 which has fewer electronic components attached thereto or incorporated therein. Furthermore, the removable electronic module 200 may be easier to maintain and/or troubleshoot than embedded electronics. The electronic module 200 may comprise flexible electronics such as a flexible printed circuit (FPC). The electronic module 200 may be configured to be electrically coupled to the garment 300.

It may be desirable to avoid direct contact of the electronic module 200 with the wearer's skin while the garment 300 is being worn. It may be desirable to avoid the electronic module 200 coming into contact with sweat or moisture on the wearer's skin. The electronic module 200 may be provided with a waterproof coating or waterproof casing. For example, the electronic module 200 may be provided with a silicone casing.

Referring to FIG. 20 , there is shown a schematic diagram of an example of the electronics module 200. The electronics module 200 comprises an interface 201, a controller 203, a power source 205, and a communicator 207.

The interface 201 is arranged to communicatively couple with the sensing component of the fabric article so as to receive a signal from the sensing component. The controller 203 is communicatively coupled to the interface 201 and is arranged to receive the signals from the interface 201. The interface 201 may form a conductive coupling or a wireless (e.g. inductive) communication coupling in some examples. That is, the connection terminal of the fabric article may be in the form of an antenna for inductively coupling to a corresponding antenna of the interface 201.

The power source 205 is coupled to the controller 203 and is arranged to supply power to the controller 203. The power source 205 may comprise a plurality of power sources. The power source 105 may be a battery. The battery may be a rechargeable battery. The battery may be a rechargeable battery adapted to be charged wirelessly such as by inductive charging. The power source 205 may comprise an energy harvesting device. The energy harvesting device may be configured to generate electric power signals in response to kinetic events such as kinetic events performed by a wearer of the garment. The kinetic event could include walking, running, exercising or respiration of the wearer. The energy harvesting material may comprise a piezoelectric material which generates electricity in response to mechanical deformation of the converter. The energy harvesting device may harvest energy from body heat of a wearer of the garment. The energy harvesting device may be a thermoelectric energy harvesting device. The power source may be a super capacitor, or an energy cell.

The communicator 207 may be a mobile/cellular communicator operable to communicate the data wirelessly via one or more base stations. The communicator 207 may provide wireless communication capabilities for the wearable article and enables the wearable article to communicate via one or more wireless communication protocols such as used for communication over: a wireless wide area network (WWAN), a wireless metroarea network (WMAN), a wireless local area network (WLAN), a wireless personal area network (WPAN), Bluetooth® Low Energy, Bluetooth® Mesh, Bluetooth® 5, Thread, Zigbee, IEEE 802.15.4, Ant, a near field communication (NFC), a Global Navigation Satellite System (GNSS), a cellular communication network, or any other electromagnetic RF communication protocol. The cellular communication network may be a fourth generation (4G) LTE, LTE Advanced (LTE-A), LTE Cat-M1, LTE Cat-M2, NB-IoT, fifth generation (5G), sixth generation (6G), and/or any other present or future developed cellular wireless network. A plurality of communicators may be provided for communicating over a combination of different communication protocols.

The electronics module 200 may comprise a Universal Integrated Circuit Card (UICC) that enables the electronics module 200 to access services provided by a mobile network operator (MNO) or virtual mobile network operator (VMNO). The UICC may include at least a read-only memory (ROM) configured to store an MNO/VMNO profile that the electronics module 200 can utilize to register and interact with an MNO/VMNO. The UICC may be in the form of a Subscriber Identity Module (SIM) card. The electronics module 200 may have a receiving section arranged to receive the SIM card. In other examples, the UICC is embedded directly into the controller 203 of the electronics module 200. That is, the UICC may be an electronic/embedded UICC (eUICC). A eUICC is beneficial as it removes the need to store a number of MNO profiles, i.e. electronic Subscriber Identity Modules (eSIMs). Moreover, eSIMs can be remotely provisioned to electronics modules 200. The electronics module 200 may comprise a secure element that represents an embedded Universal Integrated Circuit Card (eUICC).

The input unit 209 enables the electronics module 200 to receive a user input for controlling the operation of the electronics module 200. The input unit 209 may be any form of input unit capable of detecting an input event. The input event is typically an object being brought into proximity with the electronics module 200.

In some examples, the input unit 209 comprises a user interface element such as a button. The button may be a mechanical push button.

In some examples, the input unit 209 comprises an antenna. In these examples, the input event is detected by a current being induced in the first antenna. The mobile device 500 is powered to induce a magnetic field in an antenna of the mobile device 500. When the mobile device 500 is placed in the magnetic field of the antenna, the mobile device 500 induces current in the antenna.

In some examples, the input unit 209 comprises a sensor such as a proximity sensor or motion sensor. The sensor may be a motion sensor that is arranged to detect a displacement of the electronics module 200 caused by an object being brought into proximity with the electronics module 200. These displacements of the electronics module 200 may be caused by the object being tapped against the electronics module 200. Physical contact between the object and the electronics module 200 is not required as the electronics module 200 may be in a holder such as a pocket 305 of the garment 300. This means that there may be a fabric (or other material) barrier between the electronics module 200 and the object. In any event, the object being brought into contact with the fabric of the pocket will cause an impulse to be applied to the electronics module 200 which will be sensed by the sensor.

Referring to FIG. 21 , there is shown an exploded view of an example electronics module 200 according to aspects of the present disclosure. The electronics module 200 comprises a communicator 207, printed circuit board 211, power source 205, and interface 201. The interface 201 comprises a magnet 213, and two conductive prongs 215, 217. The electronics module 200 may be the electronics module 200 of FIG. 20 , but this is not required.

The components of the electronics module 200 are provided within a housing formed of a top enclosure 219 and a bottom enclosure 221. A longitudinal axis 223 extends from the top enclosure 219 to the bottom enclosure 221. The communicator 207 is provided proximate to the top enclosure 219. The bottom enclosure 221 is closest to the body of the wearer in use and the top enclosure 219 is furthest away from the body of the wearer in use. Beneficially, providing the communicator 207 proximate to the top enclosure 219 minimises the communication distance between the communicator 207 and the mobile device 500. This is particularly beneficial when the communicator 207 is a short-range communication antenna 207 such as an NFC antenna 107.

The printed circuit board 211 comprises the controller and input unit amongst other components.

The housing 219, 221 has a circular cross-sectional shape in the example of FIG. 21 but this is not required. The housing may have any cross-sectional shape such as oval, square or rectangular.

Referring to FIGS. 22 and 23 , there is shown another example electronics module 200 according to aspects of the present disclosure. The electronics module 200 has a similar internal construction to the electronics module 200 of FIG. 21 but has a different structure of interface 201 used to couple the electronics module 200 to the sensing component of the fabric article. In these Figures, the top enclosure 219 is omitted so that the internal components of the electronics module are visible.

The interface element 201 comprises two conductive pads 223, 225 that are adhesively attached to the external surface of the bottom enclosure 221 using adhesive layers 227, 229. The adhesive layers 227, 229 comprise openings 231, 233. These openings 231, 233 are aligned with openings 235, 237 provided in the bottom enclosure 221.

Pogo pins 239, 241 extend through openings 235, 237 in the bottom enclosure 221 and openings 231, 233 in the adhesive layers 227, 229 so as to electrically connect to the conductive pads 223, 225. The openings 231, 233 in the adhesive layers 227, 229 are larger than the openings 235, 237 in the bottom enclosure 221 to help ensure that adhesive does not interfere with the pogo pin mechanism or cause a potential short circuit. The pogo pins 239, 241 electrically connect the printed circuit board 211 to the conductive pads 223, 225.

Pogo pins 239, 241 are not required in all examples and other forms of force-biased conductor may be used.

The conductive pads 223, 225 are formed from conductive elastomeric material 223, 225. The conductive elastomeric material used in this example is a conductive silicone rubber material, but other forms of conductive elastomeric material may be used. Beneficially, elastomeric material such as conductive silicone rubber can have an attractive visual appearance and may easily be moulded or extruded to have branded or other visual elements. The pads 223, 225 may be textured to provide additional grip when positioned on the garment. The texture may be, for example, a ribbed or knurled texture. The elastomeric material 223, 225 shown in FIGS. 22 and 23 has a ribbed texture. The conductive pads 223, 225 are not required to be formed of elastomeric material other conductive materials such as metals or conductive fabric may be used.

The conductive pads 223, 225 together form a split-ring shape, but other shapes and arrangements are within the scope of the present disclosure.

In some examples of the present disclosure, the fabric article 100 further comprises a gripper component provided on the first surface of the base component. The gripper component is arranged to grip the fabric article to the skin surface and hold it in place even when the wearer of the fabric article is moving.

In some examples, the gripper component comprises two strips of gripper material provided along opposed edges of the electrode and two strips of gripper material provided along opposed edges of the electrode. In this way, the gripper component is provided around the periphery of the electrode. Having the gripper material around both sides of the electrode is beneficial in terms of enhancing the gripping effect, and also provides a barrier around the electrode to help reduce water ingress and/or egress.

The gripper component is not provided around the periphery of the conductive pathway in this example. Moreover, the gripper component is only provided on the first surface of the base component and is not provided on the second surface of the base component. In some examples, it may also be desirable to provide gripper component on the second surface.

In some examples, the gripper component in this example is a raised section that extends away from the first surface of the base component. This means that the gripper component has a raised or three-dimensional profile which helps place it in contact with the skin surface without requiring additional compression from the base component. The electrode still extends from the first surface to a greater extent than the gripper component.

In one example, the gripper component is formed by applying silicone tape to either side of the electrode on the first surface. Before applying the tape to the first surface of the base component, the desired application areas for the gripper component may be marked on the first surface using, for example, a particular colour. This may help a person or machine to apply the silicone tape. An example silicone tape is the Stay4Sure™ tape as provided by Stretchline Holdings 1430 Broadway Suite 307, New York, N.Y. 10018 U.S.A.

In another example, the gripper component is formed by applying a coating of silicone to the first surface of the base component. This may be formed by applying a bead of silicone material to the first surface of the base component.

In another example, the gripper component is formed by knitting a gripping yarn such as a silicone yarn after or during the process of manufacturing the rest of the fabric article. This approach can simplify the construction of the fabric article as additional steps such as the application of a silicone tape or a silicone coating are not required. An example silicone yarn is Silicotex® as provided by Massebeuf Textiles, 135 route de la Fabrique, 07380 Pont de Labeaume.

In some examples, particularly when the gripper component is formed by knitting silicone yarn, the fabric article may further comprise filler material disposed within the gripper component. The filler material comprises an expanding yarn that is knitted into the fabric article during the process of knitting the fabric article as described above. That is, the gripping component may be part of the continuous body of fabric made using the method described above. The expanding yarn used in this example is a Newlife™ polyester filament yarn manufactured by Sinterama S.p.A.

Beneficially, the filler material raises the profile of the gripper component away from the base component. This helps to increase the quality, consistency and area of contact area. This is particularly beneficial as it helps ensure contact against the skin surface without requiring the fabric article to provide additional compression such as through additional elastomeric material. The filler material maintains the shape of the gripper component and protects against deformation, buckle and roll even when they are rubbed against the skin or other surface. Moreover, using an expanding yarn means that the process of filling out the gripper component is an intrinsic part of the manufacturing process. A separate manual process of inserting filler material into already formed gripper component is not required.

In the present disclosure, the electronics module may also be referred to as an electronics device or unit. These terms may be used interchangeably.

Referring to FIGS. 24 to 28 , there are shown further examples of wearable assemblies 10 according to aspects of the present disclosure. The wearable assemblies 10 comprise fabric article 100, an electronics module 200 and a garment 300. The fabric articles 100 incorporate a plurality (two in these examples) of sensing components 107 a, 107 b. The fabric articles 100 comprise a base layer 101 having stretch properties due to, in this example, the incorporation of stretch yarn in the knitting of the base layer. The fabric articles 100 act as a stretch layer for the garment 300. The fabric articles 100 are arranged in the form of a strap/band that surrounds a circumference of the wearer when worn. The fabric articles 100 are arranged to tension the wearable article when worn. The fabric article 100/garment 300 may form chest bands, waist bands, wrist bands, arm bands, or underbands of a bra or similar garment. The examples of FIGS. 24 to 26 provide fabric articles 100/garments 300 in the form of chest bands. The examples of FIGS. 27 to 28 provide fabric articles 100/garments 300 in the form of underbands for a bra.

Providing the sensing components 107 a, 107 b as part of the same stretch layer is particularly beneficial as it reduces the chances of the two sensing components 107 a, 107 b not being accurately aligned to each other as a result of, for example, human error when attaching two separate fabric articles 100 comprising sensing components 107 a, 107 b to the garment 300.

The fabric article 100 is arranged such that the connection terminals 111 a, 111 b are positioned proximate to one another. The electrodes are spaced apart from one another. The connection terminals 111 a, 111 b are provided on an outer facing surface of the fabric article 100. The electrodes are provided on an inner facing surface of the fabric article 100.

A pocket layer 305 is attached to the fabric article 100 by side seams 315, 317. The pocket layer 305 forms a pocket space between the pocket layer 305 and the fabric article 100 sized to removably receive electronics module 200. The upper margin of the pocket layer 305 is unattached to the fabric article 100 to provide an opening for the pocket space.

The garment 300 further comprises a waterproof layer 309 attached to the fabric article 100 by adhesive layer 313. The waterproof layer 309 is a liquid impermeable layer. The waterproof layer 309 is provided in the pocket space between the fabric article 100 and the pocket layer 305. The waterproof layer 309 prevents or otherwise restricts the ingress of water, such as due to sweat, into the pocket space from the body surface when the garment 100 is worn. The waterproof layer 309 is formed from a waterproof film of material.

The waterproof layer 309 comprises recesses 311 a, 311 b that are aligned with the connection terminals 111 a, 11 b of the fabric article 100. The recesses 311 a, 311 b are openings that extend through the waterproof layer 309. Corresponding recesses are provided in the adhesive layer 313.

The pocket space is sized to removably receive an electronics module 200. When the electronics module 200 is positioned in the pocket space, the recesses 311 a, 311 b enable the interface elements of the electronics module 200 to form a communicative connection with the connection terminals 111 a, 111 b. The communicative connection may be a conductive connection between the interface elements of the electronics module 200 and the connection terminals 111 a, 111 b.

In the example of FIG. 24 , the fabric article 100 comprises a first end and a second end. The connection terminal 111 a is provided proximate to the first end. The connection terminal 111 b is provided proximate to the second end. The first end and second end are provided proximate to one another in the pocket space formed by the pocket layer 305. The first end and second end are not directly attached to one another and are spaced slightly apart from one another.

In the examples of FIGS. 25 to 28 , the fabric article 100 forms a continuous loop of material that surrounds a circumference of the wearer.

In the examples of FIGS. 24,25 . and 27, the garment 300 further comprises an inner layer 307 that is attached to the fabric article 100 by adhesive layer 319.

In the examples of FIGS. 24 and 27 the inner layer 307 covers and insulates conductive pathways of the fabric article 100 so as to prevent the conductive pathways from contacting a skin surface of the wearer. The inner layer 307 and adhesive layer 319 comprise openings 321 a, 321 b, 323 a, 323 b that are aligned with the electrodes provided on the inner surface of the fabric article 100. The inner layer 307 and adhesive layer 319 do not cover the electrodes which enables the electrodes to come into close proximity with or contact the skin surface.

In the examples of FIGS. 25, 26, and 28 , an insulating inner layer 307 is not provided. Or does not cover the conductive pathways. The fabric article 100 in these examples may be self-insulating. In the examples of FIGS. 27 and 28 , the pocket layer 305 forms the outer layer of the bra underband and surrounds the circumference of the wearer. The pocket layer 305 has substantially the same dimensions as the base layer 101 of the fabric article 100.

In the example of FIG. 28 , the fabric article 100 forms an inner layer of the bra underband. A separate elastomeric layer of the bra underband is not required. The pocket space is formed between the pocket layer 305 and the fabric article 100.

At least some of the example embodiments described herein may be constructed, partially or wholly, using dedicated special-purpose hardware. Terms such as ‘component’, ‘module’ or ‘unit’ used herein may include, but are not limited to, a hardware device, such as circuitry in the form of discrete or integrated components, a Field Programmable Gate Array (FPGA) or Application

Specific Integrated Circuit (ASIC), which performs certain tasks or provides the associated functionality. In some embodiments, the described elements may be configured to reside on a tangible, persistent, addressable storage medium and may be configured to execute on one or more processors. These functional elements may in some embodiments include, by way of example, components, such as software components, object-oriented software components, class components and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuitry, data, databases, data structures, tables, arrays, and variables. Although the example embodiments have been described with reference to the components, modules and units discussed herein, such functional elements may be combined into fewer elements or separated into additional elements. Various combinations of optional features have been described herein, and it will be appreciated that described features may be combined in any suitable combination. In particular, the features of any one example embodiment may be combined with features of any other embodiment, as appropriate, except where such combinations are mutually exclusive. Throughout this specification, the term “comprising” or “comprises” means including the component(s) specified but not to the exclusion of the presence of others.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. 

1-31. (canceled)
 32. A fabric article comprising a continuous body of weft knitted fabric, the continuous body of fabric comprises: a base component comprising a plurality of courses of non-conductive yarn and a sensing component comprising a plurality of courses of conductive yarn forming a first conductive region, a conductive pathway, and a second conductive region, wherein the first conductive region and the second conductive region are provided on opposing surfaces of the base component and are spaced apart from one another along a course direction of the fabric article, wherein the conductive pathway extends, in the course direction, along one of the surfaces of the base component between the first and second conductive regions, and wherein part of the conductive yarn forming the conductive pathway extends through the base component so as to electrically connect the first conductive region to the second conductive region.
 33. The fabric article as claimed in claim 32, wherein the first conductive region is a three-dimensional conductive region that extends away from a surface of the base component.
 34. The fabric article as claimed in claim 33, wherein the first conductive region forms a tube extending from the surface of the base component.
 35. The fabric article as claimed in claim 33, wherein a filler material is disposed within the first conductive region.
 36. The fabric article as claimed in claim 35, wherein the continuous body of fabric comprises the filler material.
 37. The fabric article as claimed in claim 36, wherein the filler material comprises an expanding yarn.
 38. The fabric article as claimed in claim 32, wherein the second conductive region is a three-dimensional conductive region that extends away from a surface of the base component.
 39. The fabric article as claimed in claim 32, wherein the first conductive region is a three-dimensional conductive region that extends away from a first surface of the base component, and the second conductive region is a three-dimensional conductive region that extends away from a second surface of the base component opposing the first surface.
 40. The fabric article as claimed in claim 32, wherein the first and second conductive regions are wider than the conductive pathway.
 41. The fabric article as claimed in claim 32, further comprising a gripper component provided on the first or second surface of the base component.
 42. The fabric article as claimed in claim 32, wherein the sensing component is a unitary knitted structure formed from a single length of conductive yarn.
 43. The fabric article as claimed in claim 32, wherein the base component is a double-knit base component.
 44. A method of manufacturing a fabric article, the method comprising forming a continuous body of weft knitted fabric comprising a base component comprising a plurality of courses of non-conductive and a sensing component comprising a plurality of courses of conductive yarn forming a first conductive region, a conductive pathway, and a second conductive region, wherein the first conductive region and the second conductive region are provided on opposing surfaces of the base component and are spaced apart from one another along a course direction of the fabric article, wherein the conductive pathway extends, in the course direction, along one of the surfaces of the base component between the first and second conductive regions, and wherein part of the conductive yarn forming the conductive pathway extends through the base component so as to electrically connect the first conductive region to the second conductive region.
 45. The method as claimed in claim 44, wherein the fabric article is manufactured using a knitting machine comprising a first bed of needles and a second bed of needles.
 46. The method as claimed in claim 45, wherein forming the continuous body of fabric comprises knitting, using one or both of the first and second beds, non-conductive yarn to form the base component.
 47. The method as claimed in claim 46, wherein forming the continuous body of fabric comprises knitting, using both the first and second beds, non-conductive yarn to form the base component.
 48. The method as claimed in any of claims 45, wherein forming the continuous body of fabric comprises knitting, using the first bed, conductive yarn to form the first conductive region.
 49. The method as claimed in claim 48, wherein knitting the conductive yarn comprises knitting, using the first bed, one or a plurality of courses of conductive yarn to form a three-dimensional conductive region that extends away from a surface of the base component.
 50. The method as claimed in claim 45, wherein forming the continuous body of fabric comprises knitting, using the second bed, conductive yarn to form the second conductive region.
 51. The method as claimed in claim 50, wherein forming the second conductive region comprises knitting, using the second bed, a plurality of courses of conductive yarn to form a three-dimensional conductive region that extends away from a surface of the base component. 